Systems and methods for applying materials to medical devices

ABSTRACT

A method for applying a predetermined pattern of material onto an elongate tubular substrate includes securing a first portion of an elongate tube having a non-circular outer perimeter to an engagement member configured to be rotated by a first motor, such that the elongate tube can be rotated in unison with the engagement member, operating the first motor to rotate the elongate tube, operating a second motor of to change the relative displacement between the elongate tube and a dispensing conduit along a longitudinal axis of the elongate tube, and expelling a conductive adhesive from a fluid dispenser through the dispensing conduit to form a predetermined pattern of the conductive adhesive on a surface of the elongate tube, the predetermined pattern of the conductive adhesive covering at least 180 degrees of the surface along the non-circular outer perimeter over a width of at least two millimeters along the longitudinal axis.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

This application is a division of U.S. patent application Ser. No.16/640,338, filed on Feb. 19, 2020, now U.S. Pat. No. 11,465,171, whichis a U.S. National Stage patent application for PCT application no.PCT/US2018/047152, filed on Aug. 21, 2018, which claims the benefit ofpriority to U.S. Provisional Application No. 62/548,129, filed on Aug.21, 2017, all of which are incorporated by reference in their entiretyherein for all purposes. Priority is claimed pursuant to 35 U.S.C. § 120and 35 U.S.C. § 119.

FIELD OF THE INVENTION

The field of the invention generally relates to systems for performingdiagnostic or therapeutic procedures within a cavity of a living body.

BACKGROUND

To add functionality to medical devices made of flexible plasticmaterials a process was developed to print an electrically conductiveflexible electronic circuit on inflatable cuffs, balloons, sleeves ormembranes. Some representative embodiments include, but are not limitedto, endotracheal tubes, nasogastric tubes. Difficulties occur when usingthis process on tubing having an outer perimeter that is non-circular oron features that have a certain degree of complexity.

SUMMARY OF THE INVENTION

In one embodiment of the present disclosure, a mechanism for applying apredetermined pattern of material onto an elongate tubular substrateincludes a first motor, an engagement member rotatable by the firstmotor and configured to reversibly grasp an elongate member having alongitudinal axis, such that rotation of the first motor rotates theelongate member around its longitudinal axis, a fluid dispenserconfigured to dispense a fluid having a first, flowable state, the fluiddispenser including an elongate dispensing conduit having a distal endhaving an orifice, the orifice configured to be placed adjacent asurface of the elongate member, a second motor configured to move atleast one of the elongate member or the elongate dispensing conduit suchthat the orifice changes its relative orientation along the longitudinalaxis of the elongate member, and wherein the distal end of the elongatedispensing conduit is configured to apply a bias on the surface of theelongate member.

In another embodiment of the present disclosure, a mechanism forapplying a predetermined pattern of material onto an elongate tubularsubstrate includes a first motor, an engagement member rotatable by thefirst motor and configured to reversibly hold an elongate member havinga longitudinal axis, such that rotation of the first motor rotates theelongate member around its longitudinal axis, a fluid dispenserconfigured to dispense a fluid having a first, flowable state, the fluiddispenser including an elongate dispensing conduit having a distal endhaving an orifice, the orifice configured to be placed adjacent asurface of the elongate member, a second motor configured to move atleast one of the elongate member or the elongate dispensing conduit suchthat the orifice changes its relative orientation along the longitudinalaxis of the elongate member, and a variable bearing spaced a firstdistance from the engagement member and including first, second andthird rollers, each of the first, second, and third rollers configuredto simultaneously contact the surface of the elongate member over acomplete rotation of the elongate member.

In yet another embodiment of the present disclosure, a toy having ahollow or tubular structure includes a first surface, one or moreelectroluminescent elements disposed on the first surface, and a circuitconfigured for operating the one or more electroluminescent elements.

In still another embodiment of the present disclosure, an antifoggingeyewear includes a frame, one or more lenses coupled to the frame, andone or more heating elements carried on at least one of the frame or theone or more lenses.

In still another embodiment of the present disclosure, a drinking glassincludes a receptacle body having an inner surface and an outer surface,and one or more heating elements carried on at least one of the innersurface or the outer surface.

In yet another embodiment of the present disclosure, method for applyinga predetermined pattern of material onto an elongate tubular substrateincludes securing a first portion of an elongate tube having anon-circular outer perimeter to an engagement member configured to berotated by a first motor, such that the elongate tube can be rotated inunison with the engagement member, operating the first motor to rotatethe elongate tube, operating a second motor of to change the relativedisplacement between the elongate tube and a dispensing conduit along alongitudinal axis of the elongate tube, and expelling a conductiveadhesive from a fluid dispenser through the dispensing conduit to form apredetermined pattern of the conductive adhesive on a surface of theelongate tube, the predetermined pattern of the conductive adhesivecovering at least 180 degrees of the surface along the non-circularouter perimeter over a width of at least two millimeters along thelongitudinal axis.

In still another embodiment of the present disclosure, a medical deviceincludes a polymeric tube having an outer cylindrical surface, a lumen,a wall, a first hole in the wall and a second hole in the wall, aconductor extending at least partially through the lumen of the tube,the conductor exiting the first hole and entering the second hole, afirst conductive adhesive layer securing the conductor to the outercylindrical surface of the tube at a portion between the first hole andthe second hole, and a second conductive adhesive layer covering theconductor and the first conductive adhesive layer at the portion betweenthe first hole and the second hole.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a machine for applying an adhesive to anelongate component, according to an embodiment of the presentdisclosure.

FIG. 2 is a top view of the machine of FIG. 1 .

FIG. 3 is a perspective view of the machine of FIG. 1 .

FIG. 4 is a detail view of the dynamic roller bearing of the machine ofFIG. 1 , according to an embodiment of the present disclosure.

FIG. 5 is a detail view of an adhesive dispenser and needle of themachine of FIG. 1 , according to an embodiment of the presentdisclosure.

FIG. 6 . Is a plan view of a controller, according to an embodiment ofthe present disclosure.

FIG. 7A is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7B is a detail view of the adhesive dispenser of FIG. 7A afteradditional tube rotation.

FIG. 7C is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7D is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7E is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7F is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7G is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7H is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7I is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 7J is a detail view of an adhesive dispenser and needle accordingto an embodiment of the present disclosure.

FIG. 8 is a perspective view of a fixture having a dynamic rollerbearing, according to an embodiment of the present disclosure.

FIG. 9 is a side view of the fixture of FIG. 8 .

FIG. 10 is a front view of the fixture of FIG. 8 .

FIG. 11 is a perspective view of a machine for applying an adhesive toan elongate component in use, according to an embodiment of the presentdisclosure.

FIG. 12 is a side view of the machine of FIG. 11 in use in a firstcondition.

FIG. 13 is a side view of the machine of FIG. 11 in use in a secondcondition.

FIG. 14 is a side view of the machine of FIG. 11 in use in a thirdcondition.

FIG. 15 is a side view of the machine of FIG. 11 in use in a fourthcondition.

FIG. 16 front view of the machine of FIG. 11 at a first stage ofoperation.

FIG. 17 front view of the machine of FIG. 11 at a second stage ofoperation.

FIG. 18 front view of the machine of FIG. 11 at a third stage ofoperation.

FIG. 19 front view of the machine of FIG. 11 at a fourth stage ofoperation.

FIG. 20 front view of the machine of FIG. 11 at a fifth stage ofoperation.

FIG. 21 front view of the machine of FIG. 11 at a sixth stage ofoperation.

FIG. 22 is a perspective view of a component during a first process offorming an electrical connection according to an embodiment of thepresent disclosure.

FIG. 23 is a perspective view of the component of FIG. 22 after a secondprocess of forming an electrical connection.

FIG. 24 is a side view of a proximity sensor according to an embodimentof the present disclosure.

FIG. 25 is a side view of a proximity sensor according to an embodimentof the present disclosure.

FIG. 26 is a side view of a proximity sensor according to an embodimentof the present disclosure.

FIG. 27 is a end view of a proximity sensor according to an embodimentof the present disclosure.

FIG. 28 is a perspective view of a balloon having electroluminescentelements.

FIG. 29 is a perspective view of a toy dart having electroluminescentelements.

FIG. 30 is a perspective view of eyeglasses having resistive heatingelements.

FIG. 31 is a perspective view of ski goggles having resistive heatingelements.

FIG. 32 is a perspective view of swim goggles having resistive heatingelements.

FIG. 33 is a side view of a drinking glass having resistive heatingelements.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Embodiments of the invention include machines and methods for producingmedical devices, medical device components or other non-medical devicesor components having predetermined patterns of material applied onelongate tubes or shafts, or contoured surfaces, and methods for usingthese machines.

Several types of medical devices utilize conductive traces carried bypolymeric bodies, shafts, tubing, or balloons. Examples of bioelectricalimpedance analysis of blood flow using electrode sensors arrayed withinbody lumens, at least some of the sensors contacting mucosal tissue canbe found in U.S. Pat. No. 5,791,349, issued on Aug. 11, 1998, andentitled “APPARATUS AND METHOD OF BIOELECTRICAL IMPEDANCE ANALYSIS OFBLOOD FLOW,” U.S. Pat. No. 5,782,774, issued on Jul. 21, 1998, andentitled “APPARATUS AND METHOD OF BIOELECTRICAL IMPEDANCE ANALYSIS OFBLOOD FLOW,” U.S. Pat. No. 6,095,987, issued on Aug. 1, 2000, andentitled “APPARATUS AND METHODS OF BIOELECTRICAL IMPEDANCE ANALYSIS OFBLOOD FLOW,” and U.S. Pat. No. 6,292,689, issued on Sep. 18, 2001, andentitled “APPARATUS AND METHODS OF BIOELECTRICAL IMPEDANCE ANALYSIS OFBLOOD FLOW,” all of which are hereby incorporated by reference in theirentirety for all purposes.

Devices having sensors and conductive traces may also be utilized toobtain an electrocardiogram signal from the body of the patient toprovide electrical timing information, as described in internationalpublication number WO2016/179563, published on Nov. 10, 2016, andentitled “SYSTEMS AND METHODS FOR INTERNAL ECG ACQUISITION,” andco-owned U.S. patent application Ser. No. 15/571,350, filed Nov. 2,2017, and entitled “SYSTEMS AND METHODS FOR INTERNAL ECG ACQUISITION,”both of which are hereby incorporated by reference in their entirety forall purposes.

Difficulties occur when applying sensors, conductive traces or otherpatterns on tubing having an outer perimeter that is non-circular or onfeatures that have a certain degree of complexity or are non-planar.FIGS. 1 and 2 illustrate a machine 100 configured to apply conductiveadhesive 102 to an elongate substrate 104, or a medical device shaft(tubing), including a catheter tube or probe body. The machine 100comprises a base 106 which includes a longitudinal slide 108 having astationary bottom portion 110 secured to the base 106 and a displaceabletop portion 112 which is slidable with respect to the stationary bottomportion 110. Attached to and moveable with the top portion 112 is amotor 114. The motor 114 is rotationally coupled to a locking member 116(or engagement member) which is configured to be securable andreleasable from an end portion 118 of the medical device shaft 104. Thelocking member 116 may comprise a chuck or a cinch or a compression lock(similar to a Touhy-Borst seal) which can be tightened or loosened (orlocked and unlocked) by a user around the medical device shaft 104.Alternatively, the locking member 106 may include a magnet, and may beconfigured to be secured to a ferrous material (e.g., a stainless steelmandrel) that is placed within a lumen of the medical device shaft 104.When the locking member 116 is locked or secured to the medical deviceshaft 104, rotation of the locking member 116 causes one-to-one rotationof the medical device shaft 104. Thus, operation of the motor 114 causesthe medical device shaft 104 to be rotated via the locking member 116.One or more gears 117 may be placed between the motor 114 and thelocking member 116 to either speed up or slow down the rotation of theclocking member in relation to the motor 114 rotation, and/or to changethe direction of rotation. Thus, the locking member 116 and medicaldevice shaft 104 may be caused to rotate in the same direction as arotor or shaft of the motor 114, or in an opposite direction than therotor or shaft of the motor. Additionally, the locking member 116 andmedical device shaft 104 may be caused to rotate the same rotationalspeed as a rotor or shaft of the motor 114, or a different rotationalspeed than the rotor or shaft of the motor (less than or greater to). Itis the object herein for the machine 100 to accommodate not only shaftor tubing 104 that has a circular outer perimeter (i.e., as viewed uponcross-section), but also shaft or tubing 104 that has a non-circularouter perimeter, including, but not limited to D-shaped,elliptically-shaped, ovoid-shaped, or oval-shaped outer perimeters. Thelocking member 116 is configured to be securable to (and releaseablefrom) circular or non-circular tubing 104 such that upon being locked tothe tubing 104, the motor 114 may be operated to rotate the lockingmember 116, thus rotating the tubing 104 around its longitudinal axis120.

A motor 122 is configured to longitudinally move the top portion 112 ofthe longitudinal slide 108 in relation to the bottom portion 110, ineither longitudinal direction (parallel to the longitudinal axis 120 ofthe tubing 104, as shown in FIG. 1 ). A controller 124 is configured tocontrol the operation of the motors 114, 122, such that any combinationof rotation and longitudinal motion of the tubing 104 may be achieved. Anumber of controllers 124 known in the art may be used, for example theTinyG™, USB-based CNC 6-axis controller sold by Synthetos, LLC ofBrookeville, Md., USA, shown in more detail in FIG. 6 .

The machine 100 includes a syringe 126, which may comprise aplunger/barrel syringe or may be an internal pressure actuated syringe.The syringe 126 in FIGS. 1-2 is attached to a pressurized injectionsystem 128 via a gas line 130 connected therebetween. The pressurizedinjection system 128 may use a number of gases, including air, filteredair, nitrogen, or carbon dioxide. The internal pressure delivered to theinterior of the barrel 132 of the syringe 126 during injection may bebetween about four pounds per square inch (0.27 atm.) and about twelvepounds per square inch (0.82 atm.), or between about six pounds persquare inch (0.41 atm.) and about eight pounds per square inch (0.54atm.), but the pressure utilized also may depend on the inner diameterand length of a hollow (hypodermic) needle 136 being used with thesyringe 126. The barrel 132 of the syringe 126 is filled with anelectrically-conductive adhesive 134, and the syringe 126/pressurizedinjection system 128 are configured to inject theelectrically-conductive adhesive 134 out through the needle 136 or othertube (metal, plastic, etc.). Turning to FIG. 5 , the needle 136 includesa proximal hub 138 which is fluidly coupled to the barrel 132 of thesyringe 126. The needle 136 also includes a distal portion 140 having anorifice 142 through which the injected electrically-conductive adhesive134 exits upon pressurization. In some embodiments, the syringe 126 maybe manually adjustable in relative position in relation to the topportion 112 of the longitudinal slide 108 (e.g., along x, y, and zaxes). The syringe 126 may also be rotatable, for example, if a curvedor generally non-straight needle 136 is utilized. In other embodiments,at least one motor 144, for example, one, two, three, or four motors,may be used to automatically adjust the location and/or angularorientation of the syringe 126, and more particularly, to adjust thelocation and orientation of the orifice 142 of the needle 136 inrelation to the tubing 104. As will be described further herein,multiple means are described to maintain the orifice 142 in closerelationship with the surface 146 of tubing 104 having a non-circularouter perimeter while the tubing 104 is rotated by the motor 114. Thesemeans may also be configured to maintain the orifice 142 in closerelationship with the surface 146 of tubing 104. For example, if thetubing 104 has a tapering outer transverse dimension or diameter thatthus causes a change in the diameter of the adjacent portion of thetubing 104 as the tubing 104 is longitudinally displaced by the motor122.

Once the orifice 142 is brought into proximity to the surface 146 of thetubing 104 to be covered or coated with the electrically-conductiveadhesive 134, a pre-programmed series of rotations of the tubing 104(via the motor 114) and longitudinal motions of the tubing 104 (via themotor 122) are performed (e.g., by the controller 124) while thepressurized injection system 128 is given the command to inject theelectrically-conductive adhesive 134 (manually, or via commands from thecontroller 124) in order to create a particular pattern of theelectrically-conductive adhesive 134 applied onto the surface 146 of thetubing 104. A separate tubing 104 after application of a pattern 148 ofthe adhesive 134 is shown in FIG. 1 supported next to the longitudinalslide 108 on top of the base 106. (The pattern 148 may includeconductive bands 150 a-c, or a longitudinal tracing 152, which may beused to electrically connect one or more of the conductive bands 150 a-cto electrical conductors (copper wire, etc.) (not shown), using solderor other joining methods. After the application of the bands 150 a-c andlongitudinal tracings 152, it may be desired to apply a dielectricmaterial over the longitudinal tracings 152, and even over a portion ofthe bands 150 a-c, or over the solder joints. The dielectric materialmay be placed into a syringe similar to the syringe 126 and applied bythe machine 100 in a similar manner to the electrically-conductiveadhesive 134. A secondary curing or solidifying process may also be usedto accelerate, optimize, or simply complete the change of either theelectrically-conductive adhesive 134 or the dielectric material, onceapplied, from liquid or flowable form to a more solid or cured form. Thesecondary operation may be performed by a transforming module (notshown) coupled to the machine 100, or used in conjunction with themachine 100. In some embodiments, temperature (e.g., elevated) may beused, using heaters such as hot air, infra-red heating, halogen lamps,radiation, cross-linking. In other embodiments, ultraviolet (UV) curingmay be incorporated. In other embodiments a chemical adhesiveaccelerator may be applied, for example by spraying. The tubing 104 maybe rotated while applying the temperature or radiation in order tocreate the desired change or set in a controlled, even fashion. Thebands 150 a-c may be incorporated to function as a number of differentelements common in medical devices, including sensors, electrodes,contacts (for electrical connection), and/or heating elements (e.g.,resistive heaters). The electrically-conductive adhesive 134 or thedielectric material may each be mixed and degassed (if needed) prior toplacement in the syringe 126, or in other embodiments, they may bepremixed and stored frozen, then defrosted prior to use. A computerprogram may be embodied in a non-transitory computer readable medium,that when executing on one or more computers provides instructions tooperate at least one of the motors 114, 122, 144.

Medical shafts and tubing often have non-circular outer perimeters.Multi-lumen extrusions typically create non-round cross-sections intubing, because of uneven cooling or uneven stresses during cooling andset of the polymeric tubing material. Many medical device shafts havecomposite constructions and include certain elements that cause anon-round cross-section (stiffening wires, electrical wires, guidewirelumens). As it is desired that the bands 150 a-c or other features suchas the longitudinal tracings 152 be placed smoothly and continuouslyonto the surface 146 of the tubing 104, regardless of the extent ofroundness or non-roundness of the tubing 104, the tubing 104 that isnon-round (has a non-circular outer perimeter) is held within themachine 100 so that it is steadied during rotation.

One or more holding members 154 are configured to cradle the tubing 104as well as to allow the distal portion 140 and orifice the 142 of theneedle 136 to have access to the portions of the surface 146 of thetubing 104 that are to be covered or coated. Turning to FIGS. 3 and 4 ,the holding member 154 includes fingers 156 a-e that, along with theholding member 154, hold rollers 158, 160, 162 which are configured toserve as a captured roller v-block to maintain three opposing linearcontacts around elongate members having a circular outer perimeter or anon-circular outer perimeter. The rollers 158, 160, 162 are spaced alongitudinal distance from the locking member 116, for example, betweenabout one cm and about 100 cm, or between about 2 cm and about 50 cm, orbetween about 2 cm and about 25 cm. For example, in FIG. 1 , holdingmember 154 a is shown cradling and allowing controlled rotation of atubing 104 having a non-circular outer perimeter, while holding member154 b is shown cradling and allowing controlled rotation of a mandrel164 that has a generally circular outer perimeter.

Turning to FIGS. 8-10 , a holding member 254 comprises fingers 256 a-hwhich are separated by access troughs 257 a-g. A longitudinal space 259extending the length of the holding member 254 is configured forallowing the placement of tubing 104 or a mandrel 164. Focusingparticularly on the first finger 256 a, a first roller 258 is rotatablearound a first pin 201 which is placed through a hole 203 in a firstprojection 205 in the finger 256 a and through a hole (not shown) in asecond projection 209 in the finger 256 a. The first roller 258 isconfigured to rotate around a first axis 211 that is thus stationary inrelation to the holding member 254. A second roller 260 is rotatablearound a second pin 213 which is placed through a hole 215 in a thirdprojection 217 in the finger 256 a and through a hole (not shown) in afourth projection 219 in the finger 256 a. The second roller 260 isconfigured to rotate around a second axis 221 that is also stationary inrelation to the holding member 254. The first roller 258 and secondroller 260 form a roller v-block at first portion 223 and second portion225, respectively. A third roller 262 is rotationally held by a pin 227through a first hole 229 in a first projection 231 of an arm 233 and asecond hole (not shown) in a second projection 237 in the arm 233. Thearm 233 is rotationally coupled to the holding member 254 at an axis239. The arm 233 thus rotates in an arc 241 around the axis 239, whichis stationary in relation to the holding member 254. The arm 233 isrotationally held by a pin 242 (through holes in the holding member254). The third roller 233 rotates around an axis 243 which isstationary in relation to the arm 233 but is moveable (not stationary)in relation to the holding member 254. A first biasing member 247 andsecond biasing member 249 are shown in FIG. 9 as helical springelements. The biasing members 247, 249 are analogous to a biasing member147 of an arm (not visible) in the holding member 154 of FIG. 3 , whichcomprises one or more elastic bands. Other types of biasing membersincluding helical and non-helical springs may be used. These includeleaf springs, living hinges and intervening compression materials thatare configured to perform within their elastic limit. Returning to FIG.9 , the first biasing member 247 is coupled to the arm 233 and a firstportion 251 of the holding member 254 and the second biasing member 249is coupled to the arm 233 and a second portion 253 of the holding member254. Thus, the roller 262 is able to adjust by moving closer to orfurther from the first roller 258 and second roller 260, to adjust tochanges in the transverse dimension of non-round tubing or shafts, thusallowing rolling three-point (line) contact at all points on the surface146 of the tubing 104 during the rotation of the tubing 104. This isdescribed in more detail in FIGS. 11-15 .

FIG. 11 illustrates the holding member 254 of FIG. 8 with a two-lumentubing 270, having a first lumen 272 and a second lumen 274, eachextending therein. The holding member 254 in FIG. 11 is modified fromthe holding member 254 of FIG. 8 in that its biasing members 247, 249have been replaced by an internal leaf spring 261 between the arm 233and the holding member 254. The tubing 270 has a non-circular outerperimeter, with a substantially D-shape. As the tubing 270 is rotated(e.g., by the motor 114 of the machine 100), the arm 233 opens orcloses, from bias applied by the leaf spring 261 so that the roller 262maintains contact with the surface 263 of the tubing 270, while theroller 262 also forces the tubing 270 against each of the rollers 258,260. Thus, the movement of the arm 233 allows the rollers 258, 260, 262to serve as a variable bearing. In FIG. 12 , the first lumen 272 andsecond lumen 274 are arrayed left and right, respectively. In FIG. 13 ,the tubing 270 has been rotated 60° in the rotational direction denotedby the curved arrow. In FIG. 14 , the tubing 270 has been rotated anadditional 30° in this same rotational direction. In FIG. 15 , thetubing 270 has been rotated in an additional 60° in this same rotationaldirection. In all cases, the rollers 258, 260, 262, each maintaincontact with the surface 263 of the tubing 270, thus stabilizing andmaintaining the orientation of the tubing. It should be noted that thelongitudinal axis 265 of the tubing 270 does not necessarily staystationary in relation to the holding member 254, as the tubing 270 isable to move up, down, left, or right as needed to maintain contact withthe rollers 258, 260, 262. As will be seen, other means are alsodescribed herein to maintain the orifice 142 of the needle 136 inproximity to the surface 263 of the tubing 270.

FIG. 7A illustrates a two-lumen, oval-shaped tube 280 being rotated in arotational direction corresponding to the curved arrow. A syringe 282injects a conductive adhesive 284 through a tubing 286 (which mayinclude hypodermic tubing or a needle) and out through an orifice 288,which applies the conductive adhesive 284 onto the surface 290 of thetube 280 creating a feature 292. The distal portion 294 of the tubing286 is pressed down against the surface 290 of the tube 280 with apreload force F, such that when the tube 280 is rotated to the positionin FIG. 7B, the distal portion 294 of the tubing 286 (and thus theorifice 288) moves down (e.g., via flexure) and stays in contact withthe surface 290 of the tube 280. The distal portion 294 is configured tostay in contact with the surface 290 of the tube 280 throughout anentire rotation of the tube 280 and throughout multiple rotations of thetube 280. Thus, a preload force F can be chosen that assures that theorifice 288 of the tubing 286 stays in proximity to the surface 290 ofthe tube 280 through all 360° of rotation of the non-circular outerperimeter. In FIGS. 7A and 7B, the preload force is biased, entirelybased on the cantilever bending of the tubing 286, which may be ametallic material like stainless steel, or may be a polymeric materialsuch as PTFE, polyethylene, or polypropylene. The diameter, length orwall thickness of the tubing 286 may be modified for each differentmaterial (modulus) chosen, in order to achieve the desired pre-loadforce. Additionally, a particular loaded displacement (strain) may bechosen to achieve the desired pre-load. Though a wide array of tubing286 may be utilized in any of the embodiments described herein, arepresentative tubing 286 includes 304 stainless steel hypodermic tubinghaving an inner diameter of between 0.0045 inches and 0.0095 inches, orbetween about 0.005 inches and about 0.007 inches.

FIG. 7C illustrates an alternative embodiment, wherein the preload biasis achieved by a biasing element instead of the cantilever bending ofthe tubing 296. The syringe 282 is fluidly attached to tubing 296 via ahollow, flexible bellows 297, which allows angular displacement(angulation) 295 between the tubing 296 and the syringe 282. Anextension spring 298 and an opposing compression spring 299 provide thepreload force F that biases the distal portion 293 of the tubing 296(and thus, the orifice 291) against the surface 290 of the tube 280. Inother embodiments, only an extension spring 298 is utilized. In otherembodiments, only a compression spring 299 is utilized. In otherembodiments, the springs 298, 299 are not utilized, but instead theflexible bellows 297 is heat-formed in a curved shape from ashape-memory polymer, thus making it the biasing element. In someembodiments, the preload bias may be achieved by a combination ofbending of the tubing 286 and the displacement of the compressionsprings 298, 299.

FIG. 7D illustrates a syringe 300 with a gas line 301 and dispenser tube302 having a transverse cut 304 at the distal end 306 and having anorifice 308 oriented transversely to the dispenser tube 302 in astandard manner. The edge 310 at the distal end 306 has not beenfilleted or otherwise smoothed, and so the tubing 312 is rotated only ina first direction 314 to apply the conductive adhesive 316 becauserotation in the opposite direction would risk the edge 310 gettingcaught on the surface 318 of the tubing 312 if a preload force F isapplied. In some embodiments, the single direction 314 is the onlyrotational direction necessary to apply a desired pattern on the surface318 of the tubing 312. FIG. 7E, however, illustrates a syringe 300 witha dispenser tube 320 which has a closed end 322 and a side hole orifice324. The side hole orifice 324 may slide along the surface 318 of thetubing 312 in either direction of rotation 326. FIG. 7F illustrates asyringe 300 with a dispenser tube 328 having a beveled end 330 with anorifice 332. The beveled end 330 minimizes the edge 334 by making it anobtuse angle, and thus allowing free rotation of the tubing 312 ineither direction of rotation 326. FIG. 7G illustrates a syringe 300 witha dispenser tube 336 having a straight proximal portion 338 and a distalportion 340 that is angled in relation to the proximal portion 338. Thetransition between the straight proximal portion 338 and the angleddistal portion 340 may be a gradual or continuous curve, or may becloser to a right angle (with some radius of curvature at the apex). Theend 342 of the dispenser tube 336 rides flush along the surface 318 ofthe tubing 312, and this allows the end 342 and the orifice 344 to stayin proximity to the surface of the tubing 312 while the tubing 312 isrotated in either direction of rotation 326. As in the othertubes/needles, etc., the dispenser tube 336 may apply a bias by means ofits cantilever bending, or by an additional biasing element, or by acombination of the two. The curvilinear shape of the dispenser tube 336may be constructed with the angle, radius or curvature and/or length tobest orient the orifice 344 of the dispenser tube 336 adjacent thesurface of the tubing 312, and the apply the desired bias on the tubing312.

The dispenser tubes 302, 320, 328, 338 shown in FIGS. 7D-7G are madewith circular tubing having a lumen with a circular cross-section.However, other configurations of dispenser tubes may be desirable,including oval, elliptical, rectangular square, triangular, or otherpolygon shapes. The orifice may also include other shapes, such ascircular, oval, elliptical rectangular, square, triangular or otherpolygonal shapes. FIG. 7H illustrates an oval-shaped dispenser tube 350having an oval-shaped orifice 352. An increased width W₁ of adhesiveapplication can be achieved with each particular lumen cross-sectionalarea. When the width W₁ is oriented along the longitudinal axis of thetubing begin covered with the adhesive, the number of rotations of thetubing that is required to form a pattern can be lessened. The patternmay include, for example, a 360° band formed on the tubing with theadhesive. The reduced number of rotations necessary can thus reduce thetime and expense of producing a component with this method. FIG. 7Iillustrates a substantially rectangular dispenser tube 354 having asubstantially rectangular orifice 356. The tube 354, by having asomewhat large aspect ratio, allows for an even larger width W₂ for eachparticular lumen cross-sectional area. FIG. 7J illustrates a compositedispenser tube 358 comprising a multitube array 360, wherein eachindividual tube 362 a-f is fluidly coupled to the syringe (e.g., via ahub), and has an end orifice 364 a-f. The composite dispenser tube 358is similar to the rectangular dispenser tube 354 if FIG. 7I, but can bemade by simply attaching several standard hypodermic tubes together in alinear array. In addition, the small diameter of each tube allows forincreased bending flexibility, if that characteristic is desired.

FIGS. 16-21 illustrate the machine 100 in use applying a conductiveadhesive 102 to tubing 104. The orifice 142 of the needle 136 of thesyringe is directed by the controller 124 (FIG. 6 ) into the trough 157a towards the finger 156 a (FIG. 16 ) and the tubing 104 is rotated (inrotational direction 111) by the motor 114 (FIG. 1 ). The adhesive 102is applied with while the tubing 104 is rotated and the motor 122longitudinally translates the tubing 104 to form a conductive band 150 a(FIG. 17 ). The relative path that the orifice 142 takes along thesurface of the tubing 104 may be a helix, or may comprise a series ofconcentric circles, arrayed longitudinally. To form a helix, the motor114 and the motor 122 may each operate at constant speeds. To form aseries of concentric circles, the motor 114 may operate while the motor122 is stopped, to form a 360° or more application of the adhesive 102,and then the motor 122 may index the tubing 104 a distance slightly lessthan the width of the applied adhesive 102 (thus to cause at least someoverlap). Then, the motor 114 may operate while the motor 122 is againstopped, to form another 360° band that slightly overlaps the first, andcreates a wider resultant band. The conductive band 150 a may cover atleast 180 degrees of the surface along the circular or non-circularouter perimeter of the tubing 104, or at least 270 degrees, or 360degrees. The conductive band 150 a may have a length of at least twomillimeters along the longitudinal axis of the tubing 104, or at leastfive millimeters, or between about one millimeter and about twentymillimeters, or between about two millimeters and about ten millimeters.The controller 124 may give commands to the motors 114, 122 so that incontinuous operation they create the helical motion, or the controller124 may include stop and start commands for the motors 114, 112 tocreate the motion comprising a series of concentric circles. FIG. 18illustrates the syringe 126/needle 136 being moved out of the trough 157a (e.g., in an upward direction) by the one or more motors 144 (FIG. 1 )via commands from the controller 124. FIG. 19 illustrates the tubing 104being moved longitudinally (to the right in FIG. 19 ) by the motor 122via commands from the controller 124. The orifice 142 of the needle 136of the syringe 126 is directed by the controller 124 into the trough 157c toward the finger 156 c (FIG. 20 ) and the tubing 104 is rotated (inrotational direction 111) by the motor 114. The adhesive 102 is appliedwith while the tubing 104 is rotated and the motor 122 longitudinallytranslates the tubing 104 to form another conductive band 150 c (FIG. 21).

FIG. 22 illustrates a medical device 370 comprising a polymeric tube 372in which an electrical connection 374 is to be formed (FIG. 23 ). Aconductor 376, comprising, for example, copper wire 371 having aninsulative cover 373, is passed through a lumen 378 in the tube 372. Twoholes 380, 382 are formed in a wall 369 of the tube 372 and theconductor 376 is passed out of the first hole 380 and back into thesecond hole 382. In some embodiments, the conductor 376 continues toextend through the lumen 378, and may even be secured (adhesively orepoxy bonded) therein. The section 384 which extends outside of the tube372 between the first hole 380 and the second hole 382 has its externalelectrical insulation material 373 removed. This may be done at thesection 384 wither before the conductor 376 is passed through the twoholes 380, 382 or afterward. A first coating or covering process is thenperformed utilizing a first conductive adhesive 392 having a firstviscosity to cover area 386 between line 388 and line 390. The firstconductive adhesive 392 may be applied manually, or with the machine 100described herein in any of its embodiments. Following this first coatingor covering process the section 384 of the exposed wire 371 is held to asurface 394 of the tube 372. Because the first conductive adhesive 392has been chosen which exhibits a sufficiently high viscosity duringapplication (e.g., in an uncured state), it is able to, for example,fill the holes 380, 382 at least partially to form a stronger joint. Itmay be desired, for example, to only apply the first conductive adhesive392 in area 391 within dotted line rectangle 393. In a second coating orcovering process, as shown in FIG. 23 , utilizing the machine 100described herein in any of its embodiments, a second conductive adhesive396 is applied over the first conductive adhesive 392 to form aconductive band 399 extending between line 397 and line 398. The secondconductive adhesive 396 may be chosen such that it has a lower viscosityduring application than does the first conductive adhesive 392, and suchthat it adheres well to the first conductive adhesive 392, assuring goodelectrical contact. The first conductive adhesive 392 may be fully setup, solidified, or cured prior to the application of the secondconductive adhesive 396, or it may be only partially set up, solidified,or cured. Thus, the first coating or covering process, the firstconductive adhesive 392 provides a “tack” or “setup” while in the secondcoating or covering process, the second conductive adhesive completesthe electrical connection 374. The electrical connection 374 thusconductively unites the wire 371 and the conductive band 399. Using thisprocess, the electrical connection 374 is significantly free from voids,and thus has a high level of reliability in the flow of current.

The needle 136 (FIG. 5 ) of the machine 100 (FIGS. 1-2 ) may be moved bycommands from the controller 124 or may be moved manually, as previouslydescribed. Additionally, one or more sensing devices may be utilized inthe machine 100 to control the movement of the needle 136, and thus thelocation of the orifice 142. A syringe 400 having a needle 402 isillustrated in FIG. 24 . A capacitive proximity sensor 404 having aplate 406 senses a gap g between the plate 406 and the needle 402. Thecapacitive proximity sensor 404 may be utilized for gross location (thegeneral target area), or finer, precision placement of the needle 402.

A syringe 400 having a needle 402 is illustrated in FIG. 25 . Aninductive proximity sensor 410 having an inductive coil 412 senses a gapg between the inductive coil 412 and the needle 402. The needle 402comprises a metallic material, for example stainless steel. Theinductive proximity sensor 410 may be utilized for gross location (thegeneral target area), or finer, precision placement of the needle 402.

A syringe 400 having a needle 402 is illustrated in FIG. 26 . A smallmagnet 424 is carried by the needle 402. A magnetic proximity sensor 420having a reed switch 422 senses a gap g between the reed switch 422 andthe magnet 424 of the needle 402. The magnetic proximity sensor 420 maybe utilized for gross location (the general target area), or finer,precision placement of the needle 402.

A syringe 400 having a needle 402 is illustrated in FIG. 27 . A lasermicrometer 431 comprising an emitter 430 and a receiver 432 transits ascanning beam 434 from the emitter 430 to the receiver 432, in thedirection of the vertical arrow. The laser micrometer 431 may beprogrammed to sense when the needle 402 begins to cross the scanningbeam 434, for example, when moving in the direction of the horizontalarrow into the beam 434. The laser micrometer 431 may be utilized as aproximity sensor for gross location (the general target area), or finer,precision placement of the needle 402. In any of the embodimentsdescribed in FIGS. 24-27 , the controller 124 may be programmed to stopthe motion of the needle 402 when a particular gap g or particularlocation of the needle 402 is sensed. A desired gap g may be input intomemory, e.g, with a user interface, such that the controller 124compares the selected gap g value.

Devices that may incorporate the improvements taught herein includestandard or modified endo-tracheal tubes, nasogastric (NG) tubes,laryngeal masks, gastric lavage tubes, gastric aspiration tubes, gastricdecompression tubes, Ewald orogastric tubes, Lavacutor® orogastrictubes, Edlich orogastric tubes, sump tubes, Salem tubes, Levin tubes,gastric suction/feeding tubes, Moss Mark IV nasal tubes, Dobbhoffnasojejunal feeding and gastric decompression tubes, nasointestinaltubes, Miller-Abbott tubes, or Sengstaken-Blakemore tubes.

Other embodiments are envisioned which do not incorporate theapplication of a conductive material, but rather a non-conductivematerial. Some embodiments may incorporate resistive, includinghighly-resistive materials, which may be used to construct a device fordelivering thermal therapy to a portion of the body via resistiveheating. Some embodiments may incorporate a radiopaque material. Devicesthat may incorporate the resistive materials include devices fortrans-urethral ablation (for example to stop bleeding), trans-uterinesterilization (e.g., fallopian tubes), electrocardiology ablationprocedures, or brachytherapy.

In additional to medical devices, other products may be constructedusing some or all of the methods and apparatus for placing patterns ofmaterial onto non-planar surfaces disclosed herein. FIG. 28 illustratesan inflatable balloon 500 comprising a first sheet of material 502 (orwall) secured to a second sheet of material 504 along aperipherally-extending seam 506. The first and second sheets maycomprise polyester, such as polyethylene terephthalate (PET). The firstand second sheets 502, 504 may be secured at the seam 506 using aflexible adhesive, like urethane adhesive, or flexible tape strips,including Uglu® adhesive strips manufactured by Morgan Adhesives Companyof Stow, Ohio, USA, or Stretchy™ Balloon Tape. An inlet 510 is locatedon the bottom of each of the first and second sheets 502, 504, and isconfigured for filling the balloon 500 with a lighter-than-air gas, suchas helium. A string 512 may be secured to the balloon 500, for example,at the inlet 510. The string 512 may be used to tie off the inlet 510,e.g. at a knot 511, or a separate plug (not shown) may be placed intothe inlet 510 to block flow of the gas out of the inlet 510. The balloon500 is shown in FIG. 28 in an inflated state, and electroluminescentcharacters 514 a-m are carried on a surface 516 of the first sheet 502.Though the electroluminescent characters 514 a-m are shown as letters,in other embodiments, the electroluminescent characters 514 a-m may bereplaced by or augmented by other electroluminescent characters,designs, or pictures. Additional electroluminescent characters 514 a-mmay be carried on a surface (not shown) of the second sheet 504. Acircuit 518 including traces 520, a multiwire cable 522, and a printedcircuit board (PCB) 524 are electrically-connected to each other (e.g.,by soldering), and to the electroluminescent characters 514 a-m. Thetraces 520 (or tracings) and the electroluminescent characters 514 a-mmay each be applied to the first sheet 502 (or the second sheet 504) bythe methods and apparatus disclosed herein. For example, a machinehaving two or more motors may be utilized to move a tubular conduit of asyringe and the inflated balloon 500 in relation to each other, to applyan electroluminescent material in a predetermined pattern and/or toapply a conductive adhesive in a predetermined pattern, to create theelectroluminescent characters 514 a-m and the traces 520, respectively.The cable 522 may be connected to the PCB 524 (at point B) and to thetraces 520 (at point A) by soldering or by electrical clips orconnectors. The PCB 524 includes a power source 526, which may includeone or more batteries. A microprocessor 525 is also carried on the PCB524, and may be configured to cause one or more of theelectroluminescent characters 514 a-m, for example, in a particularpattern or timing, to light in response to motion (sensed by anaccelerometer 527 electrically coupled to the circuit 518) or beingtouched (sensed by a capacitive or resistive touch sensor 529electrically coupled to the circuit).

Electroluminescence is an optical phenomenon and electrical phenomenonin which a material emits light in response to the passage of anelectric current. The power source 526 supplies a voltage to cause acurrent to pass through the cable 522, the traces 520, and theelectroluminescent characters 514 a-m, causing the electroluminescentcharacters 514 a-m to illuminate a message, such as “HAPPY BIRTHDAY,” ora picture or design. The PCB 524 may include one or more timer circuits528 in order to cause one or more electroluminescent character 514 toilluminate at different times. For example, the word “HAPPY” may becaused to illuminate by itself first for one second, and then both thewords “HAPPY” and “BIRTHDAY” may subsequently be illuminated togetherfor three seconds, followed by one-half second with neither the word“HAPPY” nor the word “BIRTHDAY being illuminated. In other embodiments,the one or more timer circuits 528 may be configured to cause eachletter to begin illuminating, one after the other. For example, “H”lights and stays lit, and then “A” lights so that “HA” is visible, etc.,until “HAPPY BIRTHDAY” is illuminated. In general, during a first timeperiod, a first subset of the electroluminescent characters 514 a-m islit while a second subset of the electroluminescent characters 514 a-mis not lit. During a second time period, a third subset of theelectroluminescent characters 514 a-m comprising one or more of theelectroluminescent characters 514 a-m of the second subset is lit. Insome embodiments, during the second time period, one or more of theelectroluminescent characters 514 a-m of the first subsets may be turnedoff. In some embodiments, the first subset and the second subset areboth on the same surface 516 of the balloon 500. In other embodiments,the first subset is one a first surface 516 and the second subset is ona second surface. Multiple circuits 518 may be employed in someembodiments, to provide a more complex array of flashing or lightingoptions, or to provide backup in case of the failure of one of thecircuits 518.

Examples of electroluminescent materials that may be utilized to formthe electroluminescent characters 514 include: zinc sulfide doped withmanganese, which emits yellow-orange light; powered zinc sulfide dopedwith copper, which emits green light; powdered zinc sulfide doped withsilver, which emits blue light. Other materials include: natural bluediamond doped with boron; semiconductors comprising light emittingdiodes (LEDs) using Group III or Group V elements, such as indiumphosphate, gallium arsenide, or gallium nitride; and organicsemiconductors including tris (2,2′-bipyridine) ruthenium (II)hexafluorophosphate. In some embodiments, the electroluminescentcharacters 514 may comprise a hyper-elastic light-emitting capacitor(HLEC).

FIG. 29 illustrates a toy dart 530 which may be constructed using someor all of the methods and apparatus disclosed herein. A machine havingtwo or more motors may be utilized to move a tubular conduit of asyringe and the toy dart 530 in relation to each other, to apply anelectroluminescent material in a predetermined pattern and/or to apply aconductive adhesive in a predetermined pattern, to create one or moreelectroluminescent designs 532, 534, 536 and traces 550, respectively.Electroluminescent designs 532, 534, 536 are shown in FIG. 29 , and inother embodiments may include characters (e.g., messages) or pictures.The dart 530 includes a body 538 having three fins 540 a-c secured tothe body 538 and extending radially, and a soft foam head 542. The head542 is shown with a spherical shape, but it may be ovoid, conical, orother symmetric or even non-symmetric shapes. One or more of the body538, fins 540, and head 542 may comprise a foam, for example, apolyurethane foam. The electroluminescent designs 532 have been appliedto one surface 544 of a fin 540 c, and may additionally be applied tothe other surfaces of the fins 540 a-c. The electroluminescent designs534 have been applied to the body 538 at a surface 546 between fin 540 aand fin 540 c, but may also be applied to other portions of the body538. The electroluminescent designs 536 have been applied to the head542 at one portion 548, but may additionally be applied to otherportions of the head 542. Traces 550 extend between theelectroluminescent designs 532, 534, 536, and may comprise conductiveadhesives, as described herein, and may be covered completely orpartially with a dielectric material. A flex circuit 552, may be curledand inserted within a cavity 554 in the body 538. The flex circuit 552carries one or more batteries 556 and one or more timer circuits 558,which function in the same manner as those of the balloon 500 of FIG. 28. A microprocessor 560 is also carried on the flex circuit 552, and maybe configured to cause one or more of the electroluminescent designs532, 534, 536, for example, in a particular pattern or timing, when thehead 542 of the dart 530 makes contact with an object. The flex circuit552 may include an accelerometer 562 for determining when the head 542of the dart 530 contacts an object. The microprocessor 560 may beconfigured to cause a particular pattern or sequence to illuminatedepending on the level and orientation of deceleration that is measuredby the accelerometer 562. A capacitive or resistive touch sensor 531 mayalso be incorporated into any portion of the toy dart 530. For example,the microprocessor 560 may be configured to cause a flashing of one,several, or all of the electroluminescent designs 532, 534, 536 for atime period of two, three, four, five, six, seven, eight, nine, ten,twenty, thirty, sixty or more seconds when the touch sensor 531 istouched. Alternatively or additionally, the microprocessor 560 may beconfigured to cause a flashing of one, several, or all of theelectroluminescent designs 532, 534, 536 for a time period of two,three, four, five, six, seven, eight, nine, ten, twenty, thirty, sixtyor more seconds when the accelerometer 562 outputs a signal patternindicating that the toy dart 530 has been thrown.

Antifogging eyewear are disclosed and represented by antifoggingeyeglasses 600 in FIG. 30 , antifogging ski goggles 602 in FIG. 31 , andantifogging swim goggles 604 in FIG. 32 . The eyewear 600, 602, 604include frames 606, 608, 610 and lenses 612 a, 612 b, 614, 616 a, 616 b,which are supported by the frames 606, 608, 610. The eyewear may includeresistive heater traces 618, 620, 622 applied to the frames 606, 608,610 using some or all of the methods and apparatus disclosed herein,and/or may include resistive heater traces 624, 626, 628 applieddirectly to the lenses 612 a, 612 b, 614, 616 a, 616 b using some or allof the methods and apparatus disclosed herein. In use, current is passedthrough the resistive heater traces 618, 620, 622, 624, 626, 628 bycircuits 630, 632, 634 which may include any of the elements orconfigurations of the PCB 524 or the flex circuit 552 in the priorembodiments (FIGS. 28-29 ), all of which may be connected byelectrically conductive traces 648, 650, 652. A machine having two ormore motors may be utilized to move a tubular conduit of a syringe andthe eyeglasses or goggles 600, 602, 604 in relation to each other, toapply the resistive heater traces 618, 620, 622, 624, 626, 628 or theelectrically conductive traces 648, 650, 652. The circuits 630, 632, 634may also couple to a humidity sensor 636, 638, 640 secured to aninternal surface of the lenses 612 a, 612 b, 614, 616 a, 616 b. Thehumidity sensor may comprise an SHTW2 manufactured by Sensirion ofStaefa, Switzerland. A microprocessor 642, 644, 646 carried on thecircuit 630, 632, 634 may be configured to control the amount of currentpassing through the resistive heater traces 618, 620, 622, 624, 626,628. In some embodiments, the microprocessor 642, 644, 646 may beconfigured to control the amount of current passing through theresistive heater traces 618, 620, 622, 624, 626, 628 as a function ofthe humidity measured by the humidity sensor 636, 638, 640. Any of thelenses 612 a, 612 b, 614, 616 a, 616 b may be configured to becorrecting lenses or non-correcting lenses, and may be constructed fromglass or polymer materials. The lenses 612 a, 612 b, 614, 616 a, 616 bmay be constructed for protection against the sun, and may include UVprotection and/or may be polarized.

A self-warming drinking glass 654 having a receptacle body 656comprising glass, plastic, or ceramic is illustrated in FIG. 33 . Acircuit 658 electrically connects via electrically conductive traces 660to one or more resistive heater traces 662, 663. The heater traces 662are substantially vertically-extending (or substantially longitudinal)and the heater traces 663 are substantially horizontally-extending (orsubstantially circumferential). Either of the heater traces 662, 663 canbe curved to follow the contours of the receptacle body 656. The one ormore resistive heater traces 662, 663 may be configured to cover an area664 of the receptacle body 656 that is not likely to be gripped by thehand of a user. The one or more resistive heater traces 662, 663 may bepurposely absent from a gripping area 666 of the receptacle body 656, inorder to avoid discomfort for the user caused by a burnt orsignificantly warm hand. The heater traces 662, 663 may both be appliedusing some or all of the methods and apparatus disclosed herein. Forexample, a machine having two or more motors may be utilized to move atubular conduit of a syringe and the drinking glass 654 in relation toeach other, to apply the one or more resistive heater traces 662, 663 orthe electrically conductive traces 660.

While embodiments have been shown and described, various modificationsmay be made without departing from the scope of the inventive conceptsdisclosed herein.

The ranges disclosed herein also encompass any and all overlap,sub-ranges, and combinations thereof. Language such as “up to,” “atleast,” “greater than,” “less than,” “between,” and the like includesthe number recited. Numbers preceded by a term such as “approximately”,“about”, and “substantially” as used herein include the recited numbers(e.g., about 10%=10%), and also represent an amount close to the statedamount that still performs a desired function or achieves a desiredresult. For example, the terms “approximately”, “about”, and“substantially” may refer to an amount that is within less than 10% of,within less than 5% of, within less than 1% of, within less than 0.1%of, and within less than 0.01% of the stated amount.

What is claimed is:
 1. A method for applying a predetermined pattern ofmaterial onto an elongate tubular substrate, comprising: securing afirst portion of an elongate tube having a non-circular outer perimeterto an engagement member configured to be rotated by a first motor, suchthat the elongate tube can be rotated in unison with the engagementmember; operating the first motor to rotate the elongate tube; operatinga second motor to change relative displacement between the elongate tubeand a dispensing conduit along a longitudinal axis of the elongate tube;and expelling a conductive adhesive from a fluid dispenser through thedispensing conduit to form a predetermined pattern of the conductiveadhesive on a surface of the elongate tube, the predetermined pattern ofthe conductive adhesive covering at least 180 degrees of the surfacealong the non-circular outer perimeter over a width of at least twomillimeters along the longitudinal axis.
 2. The method of claim 1,wherein the surface of the elongate tube is located at a second portionof the elongate tube, different from the first portion of the elongatetube.
 3. The method of claim 1, wherein the predetermined pattern of theconductive adhesive covers 360 degrees of the surface along thenon-circular outer perimeter over a width of at least five millimetersalong the longitudinal axis.
 4. The method of claim 1, wherein expellingthe conductive adhesive further comprises applying a bias with a distalend of the dispensing conduit against the surface of the elongate tubesuch that the distal end of the dispensing conduit remains in contactwith the surface of the elongate tube throughout rotation of theelongate tube.
 5. The method of claim 1, wherein operating the firstmotor to rotate the elongate tube further comprises simultaneouslycontacting the elongate tube with first, second, and third rollers at alocation on the elongate tube spaced a first distance from theengagement member, such that the first, second, and third rollers eachmaintain contact with the elongate tube as they rotate.
 6. The method ofclaim 5, wherein at least one of the first, second, and third rollers isconfigured to place a bias on the elongate tube.
 7. The method of claim6, wherein the at least one of the first, second, and third rollers isconfigured to bias the elongate tube against the other of the first,second, and third rollers.
 8. The method of claim 1, further comprising:accelerating or aiding a change in the conductive adhesive from a first,flowable state to a second, substantially solidified state.
 9. Themethod of claim 8, wherein accelerating or aiding the change comprisesheating the conductive adhesive.
 10. The method of claim 8, whereinaccelerating or aiding the change comprises applying ultraviolet (UV)radiation to the conductive adhesive.
 11. The method of claim 8, whereinaccelerating or aiding the change comprises applying a chemically-basedadhesive accelerator.
 12. The method of claim 1, further comprising:sensing the location of at least a portion of the dispensing conduit.13. The method of claim 12, wherein sensing the location comprises usingone or more sensor selected from the list consisting of: an inductiveproximity sensor, a magnetic proximity sensor, a capacitive proximitysensor, and a laser micrometer.
 14. The method of claim 1, wherein thepredetermined pattern of the conductive adhesive is applied to thesurface such that the expelled conductive adhesive is caused to be movedaway from the dispensing conduit as the elongate tube is rotated by thefirst motor.
 15. The method of claim 1, wherein the dispensing conduitcomprises an orifice configured to permit the conductive adhesive toexit therefrom.
 16. The method of claim 1, wherein a distal portion ofthe dispensing conduit comprises an exit location configured to permitthe conductive adhesive to exit therefrom.
 17. A method for applying apredetermined pattern of material onto an elongate tubular substrate,comprising: securing a first portion of an elongate tube to anengagement member configured to be rotated by a first motor, such thatthe elongate tube can be rotated in unison with the engagement member;operating the first motor to rotate the elongate tube; operating asecond motor to change relative displacement between the elongate tubeand a distal portion of a dispensing conduit along a longitudinal axisof the elongate tube; expelling a conductive adhesive from a fluiddispenser through the dispensing conduit and out through an exitlocation at the distal portion of the dispensing conduit to form apredetermined pattern of the conductive adhesive on a surface of theelongate tube; and maintaining the exit location in proximity to thesurface of the elongate tube during relative movement between theelongate tube and the exit location by use of a controller whileutilizing information from a sensor configured to sense the location ofat least a portion of the dispensing conduit.
 18. The method of claim17, wherein the sensor is selected from the list consisting of: aninductive proximity sensor, a magnetic proximity sensor, a capacitiveproximity sensor, and a laser micrometer.
 19. The method of claim 17,wherein the predetermined pattern of the conductive adhesive is appliedto the surface such that the expelled conductive adhesive is caused tobe moved away from the exit location as the elongate tube is rotated bythe first motor.
 20. The method of claim 17, further comprising:accelerating or aiding a change in the conductive adhesive from a first,flowable state to a second, substantially solidified state.